Removing and installing turbocharger, “single turbo engine” — VW

Removing and installing turbocharger,
“single turbo engine”
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Hose clip pliers
VAS 6340
Caution
When a mechanical fault is found on the turbocharger, e.g. a destroyed compressor impeller, it is not only sufficient to renew the turbocharger. To avoid subsequent damage, the following work must be carried out:
Check air filter container, air filter element and intake hoses for dirt.
Check the whole charge air path and charge air cooler for foreign objects.
If foreign objects are found in the charge air system, the charged air routing must be cleaned and the charge air cooler must be renewed, if necessary.
Removing
Observe rules for cleanliness
Chapter
.
Unscrew nuts
2
from connecting pipe
3
. Take care not damage
exhaust temperature sender 1
G235
1
in the process.
Unscrew bolts for connection pipe
3
on exhaust gas recirculation cooler.
Remove connecting pipe
3
.
Unscrew bolts
1
and remove heat shield
2
.
Note
There are two different heat shields.
I Large heat shield
II Small heat shield
Unscrew nuts
arrows
from top of turbocharger.
Caution
Do not loosen the screw-type clip
1
and pull back over the pressure hose. Risk of damage to the pressure hose!
Open screw-type clip
1
far enough to enable removal of pressure hose.
Release and pull off connector
2
.
Pull off vacuum hose
3
.
Pull connector
2
and hose
3
out of mounting
arrow
.
Loosen screw-type clip
4
.
Unscrew bolt
2
from pressure pipe
1
.
Lift retaining clip (not shown in illustration), pull pressure hose
1
off charge air cooler
arrow
and remove.
Release and detach connector
arrow
of
exhaust temperature sender 1
G235
. Then, lay wiring harness to one side.
Remove particulate filter
Chapter
.
Unscrew union nut
4
and banjo bolt
6
.
Remove nut
8
and remove oil supply line
5
.
Remove nuts
arrows
. The nuts cannot be seen from below or above. Use a mirror if necessary.
Unscrew
exhaust temperature sender 1
G235
3
.
Remove nuts
7
.
Note
It may not be possible to remove the spring-type clip due to its location and the restricted space. In this case, remove the rear torque reaction support
Chapter
.
Remove spring-type clip
3
with the
hose clip pliers
VAS 6340
.
Remove bolt
2
.
Cover anti-roll bar with a cloth or similar to avoid damage to paintwork.
Remove turbocharger
1
.
Once turbocharger has been removed, bolt
2
must be released from bracket
1
for reinstalling.
Installing
Installation is carried out in the reverse order; note the following:
Apply engine oil to inside of oil return hose to facilitate installation if rear torque reaction support is fitted.
Observe instructions for hose connections with screw-type clips
Chapter
.
Renew banjo bolt of turbocharger support as well as seals and gaskets.
Bolt
2
must be released from bracket
1
for reinstalling.
Place turbocharger
1
on studs and push oil return hose
4
onto oil return pipe.
Screw in bolt
2
loosely.
Caution
Note tightening sequence and procedure when bolting turbocharger on
Fig.
.
Install rear torque reaction support
Chapter
Install particulate filter
Chapter
.
Specified torques
Chapter
“
Assembly overview - turbocharger,
single turbo engine
”
Chapter
“
Assembly overview - particulate filter
”
Chapter
“
Removing and installing engine mountings
”
Noise insulation; Assembly overview - noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation